No Sweat Marks Fabric with Moisture Management Function

ABSTRACT

Examples of a knitted or woven fabric with moisture management function are described, comprising a face fabric layer with a durable water repellency (DWR) additives forming a fabric outer surface that is hydrophobic and a back fabric layer comprising a second yarn that is highly hydrophilic forming a moisture regain core to absorb the moisture and spread it across on an inside surface of the back fabric layer. The outer (face) layer of the fabric is hydrophobic due to the added DWR additives to the first yarn while the inner (back) layer of the fabric is highly hydrophilic that absorbs and spreads the moisture across the inner side of the back layer so that it dries faster making the outer surface of the face fabric layer dry thus reducing the occurrence of water I liquid spots on the face layer outer surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to PCT/CA2022/050529, filed on Apr. 7, 2022 and entitled “No Sweat Marks Fabric with Moisture Management Function”, which application claims the benefit of priority to U.S. Provisional Patent Application No. 63/173,093, filed Apr. 9, 2021, the content of which applications are hereby incorporated by reference in their entirety.

TECHNICAL FIELD

It is provided a fabric with moisture management function that reduces occurrence of moisture (liquid) spots, such as sweat spots, water spots or blood spots on its face surface.

BACKGROUND

Fabrics used in apparel designed for athletic activities are conceived with the objective of maximizing the body performance by notably controlling the body temperature and keeping the moisture away from the individual. The challenge is to manufacture such apparel which generally exhibit characteristics that enhance the performance without compromising the appearance and/or comfort of an individual. The moisture from the associated sweat generated as a result of physical exertion causes undesirable liquid spot on the face surface of the apparel. Having a fabric that reduces occurrence of moisture spots is convenient for wearers that can work out in a athletic gear and walk to get groceries or coffee without worrying about sweat marks. During hot humid days, people commuting desire to be provided with fabrics that would not show sweat marks on their clothing as well.

It is thus highly desired to be provided with improved fabrics that reduce occurrence of moisture spots on its face surface.

SUMMARY

In one aspect a knitted or woven fabric with moisture management function is provided. The fabric comprises a face fabric layer with a durable water repellency (DWR) additives forming a fabric outer surface that is mostly hydrophobic, a back fabric layer comprising a second yarn that is hydrophilic forming a moisture regain core to absorb the moisture and spread it across on an inside surface of the back fabric layer, and a connecting yarn binding together the face fabric layer and the back fabric layer.

In an embodiment, the first yarn is spun using the DWR additives inside the yarn.

In another embodiment, the first yarn has the DWR additives finish.

In a supplemental embodiment, the fabric is a weft or warp knitted fabric or a woven fabric.

In one aspect, the moisture regain of the back fabric layer is in the range of 4%-18%.

In another aspect, the first yarn is a synthetic polymer selected from a group of a nylon, a polyester, a polypropylene, an acrylic or any bland combination thereof.

In another embodiment, the first yarn is nylon 6.6 with denier range of 20 D-100 D and number of filaments from 10 to 186.

In another aspect, the face fabric layer further comprising a third yarn joined together with the first yarn such that the third yarn is on the inside and the first yarn is on the outside of the face fabric layer.

In one aspect, the second yarn comprises a natural or a regenerated cellulosic fiber selected from a group consisting of a cotton, silk, wool, modal, micro-modal, viscose rayon, lyocell, cupro, artificial silk, regenerated cellulosic fibers, regenerated protein fibers and any combination thereof.

In an embodiment, the third yarn is an elastane.

In a further embodiment, the elastane has a denier in the range of 10 D to 70 D.

In a supplemental embodiment, the face fabric layer is a composite blend of a synthetic polymer with the DWR additives plaited with an elastane.

In another aspect, the back fabric layer further comprising a fourth yarn joined together with the second yarn such that the fourth yarn is on the inside and the second yarn is on the outside of the back fabric layer.

In one aspect, the second yarn is a hydrophilic synthetic polymer selected from a group consisting of a nylon, a modified polyester, a modified polypropylene, a modified acrylic and a combination thereof.

In another aspect, the fourth yarn is an elastane.

In one aspect, the elastane has a denier in the range of 10 D to 70 D.

In another embodiment, the second fabric layer is a composite blend of a natural fiber or a regenerated cellulosic fiber plaited with an elastane.

In a further embodiment, the back fabric layer is peached or brushed to increase its surface area.

In another aspect, the connecting yarn is at least a single strand.

In a further embodiment, the connecting yarn is a synthetic polymer.

In another aspect, the connecting yarn is an elastane.

In another aspect, an outer surface of the face fabric layer is finished with a durable water repellency (DWR) coating.

In another aspect, an outer surface of the back fabric layer comprises a wicking finish.

In one aspect, the fabric is knitted from a double jersey plaited construction.

In one aspect the fabric is a plaited single jersey fabric.

In one aspect the fabric is a plaited warp knitted fabric.

In one aspect the fabric is a double weave woven fabric.

In another embodiment, the fabric is a pique fabric or a tricot fabric.

In one aspect, an article of apparel comprising the fabric as defined herein is provided.

BRIEF DESCRIPTION OF DRAWINGS

Reference will now be made to the accompanying drawings.

FIG. 1 illustrates a schematic representation of a double jersey plaited construction fabric as encompassed herein in accordance to an embodiment

FIG. 2 illustrates a schematic representation of a no-sweat piqué fabric as encompassed herein in accordance to an embodiment, showing the four courses or repeat that makes the piqué.

FIG. 3 illustrates a double weave fabric as encompassed herein in accordance to an embodiment

FIG. 4 illustrates a tricot fabric construction encompassed herein in accordance to an embodiment

DETAILED DESCRIPTION

In accordance with the present disclosure, it is provided a knitted or woven fabric with moisture management function comprising a face fabric layer with a first yarn that has durable water repellency (DWR) additives or a DWR finish forming an outer surface that is hydrophobic or mostly hydrophobic, a back fabric layer comprising a second yarn that is highly hydrophilic forming a moisture regain core to absorb the moisture and spread it across on an inside surface of the back fabric layer, and a connecting yarn binding together the face fabric layer and the back fabric layer. The moisture that is absorbed and spread across the inside surface between the back fabric layer and the face fabric layer evaporates over time through the face fabric layer. The outer (face) layer of the fabric is hydrophobic due to the added DWR additives or DWR finish to the first yarn while the inner (back) layer of the fabric is hydrophilic that absorbs and spreads the moisture across the inner side of the back layer so that it dries faster making the outer surface of the face fabric layer dry thus avoiding or reducing the occurrence of liquid spots on the face layer outer surface.

As seen in FIG. 1 , the fabric 10 comprises a back (inner) layer 12 which is the layer next to the skin of a wearer and a face (outer) layer 14 which correspond to the layer of the fabric 10 facing the exterior and away from the skin of the wearer. As illustrated in FIG. 1 , in an embodiment, a connecting yarn 16 binds together the back fabric layer 12 and the face fabric layer 14 connecting the fabric 10 together. The moisture from a wearer skin is pushed through the back fabric layer 12 and it will spread on the backside of the fabric 10, essentially from side A (the skin of the wearer face) towards B (the exterior face and away from the skin of the wearer). The absorbed moisture spread therein evaporates out over the time without making sweat marks showing on the face 14 of the fabric 10.

The face fabric layer 14 comprises a first yarn 23 that comprises the durable water repellency (DWR) additives or DWR finish therein thus forming a fabric outer surface that is hydrophobic thus avoiding or reducing the occurrence of a sweat mark on the outer surface of the fabric 10 during sweaty activities. For example, the first yarn 23 can be spun using a DWR additives inside the yarn 23 or the yarn 23 can have a DWR finish. The back fabric layer 12 comprises a second yarn 18 that is hydrophilic forming a moisture regain core that absorbs the moisture from the skin and spreads it across on an inside surface of the back fabric layer therefore making it dry faster while keeping the outer surface of the face layer 14 without sweat mark visible on the outside of the fabric 10.

In the illustrated embodiment of FIG. 1 , the face fabric layer 14 further comprises a third yarn 24 knitted or woven together with the first yarn 23 such that the third yarn 24 is on the inside while the first yarn 23 is on the outside of the face layer 14. In some implementations, the first yarn 23 can be a synthetic polymer, such as for example but not limited to, a nylon, a polyester, a polypropylene, an acrylic or any bland combination thereof. In one embodiment, the first yarn 23 can be a 15 to 100 denier(D)/10 to 184 filaments (F) 6.6 nylon with DWR additives. The third yarn 24 can be an elastane, such as for example 10 D to 70 D spandex. The third yarn can also be the same DWR yarn that is used on face. The face fabric layer 14 can be a composite blend of a synthetic polymer with DWR additives plaited with an elastane or with DWR finish. In various embodiments, the outer surface of the face layer 14 comprises DWR finish.

The back fabric layer 12 comprises a second yarn 18 that is hydrophilic forming a high moisture regain thus forming a hydrophilic moisture regain core of the fabric 10. For example, the moisture regain of the second yarn 18 can be in a range of 4%-18%. The second yarn 18 can be any suitable natural fiber or a regenerated cellulosic fiber. For example, the second yarn 18 is selected from a group consisting of a cotton, silk, wool, modal, micro-modal, viscose rayon, lyocell, cupro, artificial silk and any combination thereof. In some implementations, the second yarn 18 can be hydrophilic synthetic polymer, such as for example, the second yarn 18 can be selected from a group consisting of a nylon, a polyester, a polypropylene, an acrylic and a combination thereof. The back fabric layer 12 further comprises a fourth yarn 20 knitted or woven together with the second yarn 18 such that the forth yarn 20 is on the inside and the second yarn 18 is on the outside of the back fabric layer 12. The fourth yarn 20 can also be a synthetic polymer, such as elastane. For example, the fourth yarn 20 can be 30 D or 40 D spandex. In one embodiment, the back fabric layer 12 can be a composite blend of a natural fiber, hydrophilic synthetic polymer or a regenerated cellulosic fiber plaited with an elastane. The face DWR and back side hydrophilic yarns can be on their own without any plaiting with spandex. In another embodiment, the back fabric layer 12 can be a composite blend of a fully hydrophilic synthetic polymer, such as nylon, plaited with an elastane. One means to increase the hydrophilic nature of the back layer 12 is to increase its surface area. Accordingly, it is encompassed that an outer side (facing skin) of the back fabric layer 12 can be peached or brushed to increase its surface area.

The connecting yarn 16 is binding together the face fabric layer 14 and the back fabric layer 12 and can be at least a single strand yarn. In one implementation, the connecting yarn 16 can be an elastane. For example, the connecting yarn 16 can be 10 D to 70 D spandex. In some implementations, the connecting yarn 16 can be a synthetic polymer such as for example a nylon, a polyester, a polypropylene, an acrylic, a polyacrylic or a combination thereof. Alternatively, the connecting yarn 16 can be a natural fiber such as for example a cotton, silk, wool, modal, micro-modal, rayon, lyocell, viscose or a combination thereof. The connecting yarn is preferably a zig-zag structure between the back fabric layer 12 and the face fabric layer 14. The connecting yarn 16 can be single strand or multiple strands. Each strand of the plurality of strands of the connecting yarn 16 can have independent zig-zag structure. The connecting yarn 16 can also be a yarn with DWR ingredient.

In one implementation, the outer surface of the face fabric layer 14 can be finished with a durable water repellency (DWR) coating to further reduce the occurrence of water or sweat spots on the outer surface of the fabric 10. For example, the DWR coating can be printed on the outer surface of the face fabric layer 14 once the face layer is finished. For example, the DWR coating can be printed, such as for example screen printed, inkjet printed, or laminated, or spray coated. In one implementation, the DWR coating can have a pre-determined pattern to provide moisture channelling out of the face layer 14 for faster drying. In one embodiment, the outer surface of the back fabric layer 12 can have a wicking finish, such as for example by adding a chemical finish containing a hydrophilic molecule that attaches to the outer surface of the back fabric layer 12.

In another embodiment, as depicted in FIG. 3 , a double weave fabric is encompassed wherein a first yarn 23 is also connecting the face layer 14 with the back fabric layer 12. In this embodiment, the face layer 14 comprises yarns 23 finished with DWR. Thus, the double weave fabric comprises a backside of the fabric being hydrophilic and the face side with DWR yarn.

As described herein, in some embodiments, the described fabric 10 is made with a knitting construction which can be a weft knitted or wrap knitted structure. For example, the fabric can be a double jersey plaited construction for example (as shown in FIG. 1 ) or Tricot warp knit structure (as shown in FIG. 4 ).

In an alternate embodiment, it is disclosed a fabric 100 wherein the back layer comprises an hydrophilic yarn 54 (FIG. 2 ). The hydrophilic yarn 54 in the illustrated embodiment is made of a natural fiber or a regenerated cellulosic fiber, preferably modal or a hydrophilic synthetic polymer. The connecting yarn 50 is a composite blend of a synthetic polymer with DWR additives plaited with an DWR finish. The face fabric layer comprises a yarn 52 and a face fabric or first yarn 56 knitted or woven together with the connecting yarn 50 such that the yarn 52 is on the inside while the first yarn 56 is on the outside of the face layer. The fabric 100 is knitted or “pique”. As encompassed herein, it is understood that pique is a traditional woven style with a waffle-knit structure. The resulting double weave structure can be seen from the face fabric layer yarns having twice as many threads as the back layer yarns, thus creating raised and recessed areas in the material. This allows different patterns to be woven. In the illustrated implementation, the pique construction is a repeat of four courses however there can be various iterations of this structure without departing from the scope of the invention. The first yarn 56 is a composite blend of a synthetic polymer with DWR additives plaited with an DWR finish. The yarn 52 is an elastane, such as for example 5D spandex. A seen in FIG. 2 , four courses or repeat are represented that makes it a pique fabric 100.

As encompassed herein, the knitted fabric described herein with moisture management function and no sweat marks showing on its face can be used in any type of articles of apparel including shirts, headwear, coats, jackets, pants, underwear, gloves, socks, and footwear.

As demonstrated herein, the fabric properties were tested and the Moisture Management Test (MMT) results confirmed that the salt solution used during the testing didn't penetrate the fabric during the test. The fabric although blocks water, is air permeable, which is a preferable attribute when thermal comfort is concerned.

Based on the results, it is clear that fabric provided herein shows unique engineered moisture blocking property.

EXAMPLE I Fabric Tested Properties

The liquid moisture management properties of textile fabric as depicted in

Figures was tested using a Moisture Management Tester (MMT). The fabric was put between two layers of sensors (top and bottom layer of sensor) with the fabric face side facing downward. A salt solution of 0.2 ml was applied to the fabric back side (skin contact side of the fabric). Thus, “Top” is skin contact side/back side of fabric; “Bottom” is outer side/face side of fabric. The Table 1 below provides the results.

TABLE 1 Standard Liquid moisture management indices Average deviation Grade* Top wetting time, WTT (second) 2.93 1 02 5 Bottom wetting time, WTB (second) 120 0 1 Top absorption rate, ART (%/second) 55.8 6.2 4 Bottom absorption rate, 0 0 1 ARB (%/second) Top max wetting radius, MWRT (mm) 25.0 0 5 Bottom max wetting radius, 0 0 1 MWRB (mm) Top spreading speed, SST (mm/second) 4.62 1.06 5 Bottom spreading speed, 0 0 1 SSB (mm/second) One way transport capability, R (%) −1100 50 1 Overall moisture management 0 0 1 capacity, OMMC *Grade represents a textile grading from 1 to 5, 5 being the best that meets the desired function and 1 being the worst - does not conform to the desired outcome of a material.

The liquid absorption property of the fabric was tested wherein the back side (skin contact side) was in contact with the applied test liquid (distilled water). The liquid absorption rate by horizontal wicking (at 20-80% absorbent capacity) in gram per second was of 0.011.

As for the drying rate of the textile at its absorbent capacity, an air flow method was used. The test conditions were: air temperature—21+1° C.; relative humidity—65+2%; air flow direction—vertical air flow from fabric back side to fabric face side; air speed before mounting the fabric—2.5+0.5 m/s; and air speed after mounting the fabric—0.10 m/s. What was observed is that water was unable to pass through the fabric.

A quick dry method was further used as this test method determines the drying rate of a fabric based on the evaporation rate that occurs at the approximate water absorbent capacity. Test specimen is mounted on a hoop. There is vertical air flow passing through the fabric (air flow perpendicular to the fabric surface).The higher the drying rate of the fabric, the better the drying performance it has. The test conditions were: air temperature—21+1° C.; relative humidity—65+2%; temperature of hot plate—37+1° C. with fabric back side (skin contact side) in contact with hot plate; and air speed—1.5±0.5 m/s (horizontal air flow over the surface of the fabric). The drying rate measured was of 1.66 mL/h.

In order to measure the fabric air permeability, a method was used to measure the drying rate of the fabric, exposed to a prescribed volume of water, while in contact with a heated plate set at 37° C., the simulated skin surface temperature. There is horizontal air flow over the surface of fabric. The higher the drying rate of the fabric, the better the drying performance it has. At a test pressure of 125 Pa over a 38 cm2 test area, the following measurement were taken.

TABLE 2 Unit Value Air Permeability Average cfm 34.8 Air Permeability Maximum cfm 36.2 Air Permeability Minimum xfm 33.8 CV % 2.2

The total heat loss in a standard environment of fabric provided herein was tested at the following atmospheric conditions: an air temperature: 25.0+0.1° C.; a relative humidity of 65+4% R.H.; for least 12 hours (specimen 5 mm thick)/At least 24 hours (specimen>5 mm thick).

The actual test conditions were: air temperature—25.0+0.1° C.; relative humidity—65+3% R.H.; air speed—1.0±0.1 m/s (horizontal air flow over the surface of the fabric); temperature of hotplate—35.0+0.1° C.; and orientation of test specimen—specimens lied flat across the measurement unit with the side normally facing the human body towards the measuring unit. Fabric back side (skin contact side) is in contact with hotplate. Below are the values measured:

-   -   Mean intrinsic thermal resistance of sample alone, Rcf (K×m²/W):         0.015     -   Mean apparent intrinsic evaporative resistance of sample, R_(ef)         ^(A) (kPa×m²/W): 0.002     -   Total heat loss, Q_(t) (W/m²): 796

While the disclosure has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modifications and this application is intended to cover any variations, uses, or adaptations including such departures from the present disclosure as come within known or customary practice within the art and as may be applied to the essential features hereinbefore set forth, and as follows in the scope of the appended claims. 

1. A fabric with moisture management function comprising: a face fabric layer comprising a first yarn having a durable water repellency (DWR) additives or a DWR finish forming a fabric outer surface being mainly hydrophobic; a back fabric layer comprising a second yarn having high moisture regain fibers, the second yarn being mainly hydrophilic forming a moisture regain core to absorb a moisture and spread it across on an inside surface of the back fabric layer; and a connecting yarn binding together the face fabric layer and the back fabric layer, wherein the connecting yarn is an elastane.
 2. The fabric of claim 1, wherein the first yarn is spun using the DWR additives inside the yarn.
 3. The fabric of claim 1, wherein the first yarn has the DWR finish.
 4. The fabric of claim 1, wherein the first yarn is a synthetic polymer.
 5. The fabric of claim 4, wherein the first yarn is selected from a group consisting of a nylon, a polyester, a polypropylene, an acrylic and any blend combination thereof.
 6. The fabric of claim 5, wherein the first yarn is nylon 6.6 with denier range of 20 D -100 D and number of filaments from 10 to
 186. 7. The fabric of claim 5, wherein the first yarn is polyester.
 8. The fabric of claim 1, wherein the face fabric layer further comprises a third yarn joined together with the first yarn.
 9. The fabric of claim 8, wherein the third yarn is on the inside and the first yarn is on the outside of the face fabric layer.
 10. The fabric of claim 7, wherein the third yarn is an elastane.
 11. The fabric of claim 10, wherein the elastane has a denier in the range of 10 D to 70 D.
 12. The fabric of claim 8, wherein the face fabric layer is a composite blend of a synthetic polymer with the DWR additives or the DWR finish plaited with an elastane.
 13. The fabric of claim 1, wherein the second yarn comprises a natural fiber or a regenerated cellulosic fiber.
 14. The fabric of claim 13, wherein the second yarn is selected from a group consisting of a cotton, silk, wool, modal, micro-modal, viscose rayon, lyocell, cupro, artificial silk, regenerated cellulosic fibers, regenerated protein fibers and any combination thereof.
 15. The fabric of claim 1, wherein the back fabric layer further comprises a fourth yarn joined together with the second yarn.
 16. The fabric of claim 15, wherein the fourth yarn is on the inside and the second yarn is on the outside of the back fabric layer.
 17. The fabric of claim 15, wherein the fourth yarn is an elastane.
 18. The fabric of claim 17, wherein the elastane has a denier in the range of 10 D to 70 D.
 19. The fabric of claim 15, wherein the back fabric layer is a composite blend of a natural fiber or a regenerated cellulosic fiber plaited with an elastane.
 20. The fabric of claim 1, wherein the second yarn is a hydrophilic synthetic polymer.
 21. The fabric of claim 20, wherein the second yarn is selected from a group consisting of a nylon, a modified polyester, a modified polypropylene, a modified acrylic and a combination thereof.
 22. The fabric of claim 21, wherein the second yarn is modified polyester.
 23. The fabric of claim 1, wherein the moisture regain of the back fabric layer is in the range of 4%-18%.
 24. The fabric of claim 1, wherein the back fabric layer is peached or brushed to increase its surface area.
 25. The fabric of claim 1, wherein the connecting yarn is at least a single strand.
 26. The fabric of claim 1, wherein an outer surface of the back fabric layer comprises a moisture wicking finish.
 27. The fabric of claim 1, wherein the fabric is a weft or warp knitted fabric.
 28. The fabric of claim 1, wherein the fabric is a plaited warp knitted fabric.
 29. An article of apparel comprising a fabric with moisture management function, the fabric comprising: a face fabric layer comprising a first yarn having a durable water repellency (DWR) additives forming a fabric outer surface being mainly hydrophobic; a back fabric layer comprising a second yarn having high moisture regain fibers, the second yarn being mainly hydrophilic forming a moisture regain core to absorb a moisture and spread it across on an inside surface of the back fabric layer; and a connecting yarn binding together the face fabric layer and the back fabric layer, wherein the connecting yarn is an elastane.
 30. The article of apparel of claim 29, wherein the face fabric layer further comprises a third yarn joined together with the first yarn, wherein the third yarn is on the inside and the first yarn is on the outside of the face fabric layer; and/or wherein the back fabric layer further comprises a fourth yarn joined together with the second yarn such that the fourth yarn is on the inside and the second yarn is on the outside of the back fabric layer. 